Reclosable Package and Method of Making the Same

ABSTRACT

A reclosable package includes a first side panel and a second side panel. The first panel defines a right side edge portion, a left side edge portion, a bottom edge portion, and a pleated portion. The second panel defines a right side edge portion, a left side edge portion, a bottom edge portion, and a hooded portion. A first seam joins the right side edge portion of the first panel with the right side edge portion of the second panel. A second seam joins the left side edge portion of the first panel with the left side edge portion of the second panel. A third seam joins the bottom edge portion of the first panel with the bottom edge portion of the second panel. A line of weakness joins the pleated portion of the first panel with the hooded portion of the second panel.

FIELD

The present disclosure relates to packages and methods of making packages, and more particularly, to sealed reclosable packages and a method of making the same.

BACKGROUND

The field of disposable absorbent articles includes a wide variety of consumer products, including diapers, bibs, wipes, sanitary napkins, tampons, etc. In some cases, the absorbent articles are packaged in a primary package, such as a polybag. A plurality of primary packages containing absorbent articles may be packaged in a secondary package, such as a cardboard box.

Primary packages for containing absorbent articles may include opposing first and second panels. Each panel may define a top edge portion, a bottom edge portion, a left side edge portion, and a right side edge portion. The first and second panels may be joined at a first seam along left side edge portions of the first and second panels and at a second seam along right side edge portions of the first and second panels. The primary package may include a reclosable feature along a top or bottom edge portion of the package for opening and closing the packages. In some primary packages, the reclosable features may include a lid, tape tab fastener, hook and loop fastener, snap, button, or latch, for example. However, adding reclosable features to the primary package may add cost and complexity to the manufacturing of the package.

Some primary packages include an integrated reclosable feature, such as a hood, in the second panel of the primary package. The hood may be positioned proximate to the top or bottom edge portion of the primary package. The hood may be configured in a closed configuration and an open configuration. In the closed configuration, the hood may cover the absorbent articles contained therein. In the open configuration, the hood may be folded away from the first panel to create an opening in the package that exposes the absorbent articles contained therein. However, the first and second panels may be integrally connected in the portion of the panels opposite the hood. As such, the hood may provide the only access to the primary package for inserting absorbent articles during the packaging process, and for removing the absorbent articles from the primary package at the time of use by the consumer. Without using additional refastenable features, the package may not be sealed at the time of purchasing the primary package of absorbent articles because of the opening created by the hood. Consequently, the absorbent articles may be subject to tampering or contamination before the package of absorbent articles is purchased by the consumer.

Therefore, it would be beneficial to provide a reclosable primary package that is sealed at the time of purchase. Moreover, it would be beneficial to provide a primary package that is reclosable without the need for additional reclosable features. Additionally, it would be beneficial to provide a sealed reclosable package that is able to be filled with absorbent articles using automated packaging processes.

SUMMARY

Aspects of the present disclosure include a reclosable package comprising a first panel and a second panel. The first panel defines a right side edge portion, a left side edge portion, a bottom edge portion, and a pleated portion. The second panel defines a right side edge portion, a left side edge portion, a bottom edge portion, and a hooded portion. The first and second panels combine to define an interior and an exterior of the package. A first seam joins the right side edge portion of the first panel with the right side edge portion of the second panel. A second seam joins the left side edge portion of the first panel with the left side edge portion of the second panel. A third seam joins the bottom edge portion of the first panel with the bottom edge portion of the second panel. A line of weakness joins the pleated portion of the first panel with the hooded portion of the second panel.

Aspects of the present disclosure include a reclosable package comprising a first panel and a second panel. The first panel defines a right side edge portion, a left side edge portion, a bottom edge portion, and a pleated portion. The second panel defines a right side edge portion, a left side edge portion, a bottom edge portion, and a hooded portion. The first and second panels combine to define an interior and an exterior of the package. A first seam joins the right side edge portion of the first panel with the right side edge portion of the second panel. A second seam joins the left side edge portion of the first panel with the left side edge portion of the second panel. A line of weakness joins the pleated portion of the first panel with the hooded portion of the second panel. The bottom edge portion of the first panel and the bottom edge portion of the second panel combine to define an opening in the package.

Aspects of the present disclosure include a method of forming a reclosable package, the method comprising the steps of: advancing a continuous length of material in a machine direction, wherein the continuous length of material has a first side and a second side and defines a first edge region and a second edge region separated along a cross direction by a third region; forming a line of weakness along the machine direction of the central region of the continuous length of material; folding the continuous length of material along the central region to form a first continuous fold that extends in the machine direction; folding the first continuous panel to form a continuous pleat, wherein the continuous pleat comprises second and third continuous folds that form first, second, and third overlapping continuous pleated portions, wherein the second and third continuous pleated portions are positioned between the first continuous pleated portion and the second panel, wherein the line of weakness overlaps the second continuous pleated portion, wherein the second and third continuous folds extend in the machine direction; cutting the continuous length of material in the cross direction to form a discrete package, wherein the discrete package comprises a first panel, wherein the first panel defines a right side edge portion, a left side edge portion, a bottom edge portion, and a pleated portion; and a second panel, wherein the second panel defines a right side edge portion, a left side edge portion, a bottom edge portion, and a hooded portion, wherein a line of weakness joins the pleated portion of the first panel with the hooded portion of the second pane; forming a first seam that joins the right side edge portion of the first panel with the right side edge portion of the second panel; and forming a second seam that joins the left side edge portion of the first panel with the left side edge portion of the second panel, wherein the bottom edge portion of the first panel and the bottom edge portion of the second panel combine to define an opening in the package.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front, perspective view of a sealed, reclosable package.

FIG. 2 is a back, perspective view of a sealed, reclosable package.

FIG. 3 is a sectional view of the sealed, reclosable package of FIG. 1 taken along lines 3-3.

FIG. 4A is a front, perspective view of a sealed, reclosable package having a plurality of absorbent articles contained therein.

FIG. 4B is a back, perspective view of a sealed, reclosable package having a plurality of absorbent articles contained therein.

FIG. 5 is a perspective view of a reclosable package with a hooded portion arranged in a first configuration.

FIG. 6 is a perspective view of a reclosable package with a hooded portion arranged in a second configuration.

FIG. 7 is a front, perspective view of a reclosable package with a hooded portion forming an opening in the package.

FIG. 8 is a front, perspective view of a sealed, reclosable package.

FIG. 9 is a sectional view of the sealed, reclosable package of FIG. 8 taken along line 9-9.

FIG. 10 is a top, plan view of a sealed, reclosable package.

FIG. 11 is a front, perspective view of a sealed, reclosable package having a handle.

FIG. 12A is a top, perspective view of a wicketed bag.

FIG. 12B is a back, perspective view of a wicketed bag.

FIG. 13 is a cross-sectional view of the wicketed back of FIG. 12A taken along line 13-13.

FIG. 14 is a top, perspective view of a stack of wicketed bags.

FIG. 15 is a schematic, plan view of a continuous length of material.

FIG. 16 is a schematic, plan view of a continuous length of material having a continuous line of weakness.

FIG. 17 is a schematic, plan view of a continuous length of material having a continuous line of weakness and a plurality of intermittently spaced wicket apertures.

FIG. 18 is a schematic, plan view of a continuous length of material folded about a first continuous fold line.

FIG. 19 is a schematic, cross-sectional view of the continuous length of material of FIG. 18 taken along line 19-19.

FIG. 20 is a schematic, plan view of a continuous length of material having a continuous gusset.

FIG. 21 is a schematic, cross-sectional view of the continuous length of material of FIG. 20 taken along line 21-21.

FIG. 22 is a schematic, plan view of a continuous length of material having a continuous gusset and a continuous pleat.

FIG. 23 is a schematic, cross-sectional view of the continuous length of material of FIG. 22 taken along line 23-23.

FIG. 24 is a schematic, plan view of a wicketed bag having a wicket panel.

FIG. 25 is a schematic, plan view of a wicketed bag.

DETAILED DESCRIPTION

The following definitions may be useful in understanding the present disclosure.

“Absorbent article” is used herein to refer to consumer products whose primary function is to absorb and retain soils and wastes. “Diaper” is used herein to refer to an absorbent article generally worn by infants and incontinent persons about the lower torso. The term “disposable” is used herein to describe absorbent articles which generally are not intended to be laundered or otherwise restored or reused as an absorbent article (for example, they are intended to be discarded after a single use and may also be configured to be recycled, composted or otherwise disposed of in an environmentally compatible manner).

“Longitudinal” means a direction running substantially perpendicular from a waist edge to a longitudinally opposing waist edge of an absorbent article when the article is in a flat out, uncontracted state, or from a waist edge to the bottom of the crotch, i.e. the fold line, in a bi-folded article. Directions within 45 degrees of the longitudinal direction are considered to be “longitudinal.” “Lateral” refers to a direction running from a longitudinally extending side edge to a laterally opposing longitudinally extending side edge of an article and generally at a right angle to the longitudinal direction. Directions within 45 degrees of the lateral direction are considered to be “lateral.”

“Machine direction” (MD) is used herein to refer to the direction of material flow through a process. In addition, relative placement and movement of material can be described as flowing in the machine direction through a process from upstream in the process to downstream in the process. “Cross direction” (CD) is used herein to refer to a direction that is not parallel with, and usually perpendicular to, the machine direction.

“Sealed” refers herein to a package having an interior that is inaccessible until the package is ruptured.

The present disclosure relates to reclosable packages for containing absorbent articles, and more particularly, relates to sealed reclosable packages and methods of making and using the same. Reclosable packages of the present disclosure may include a first panel and an opposing second panel. The first panel defines a right side edge portion, a left side edge portion, a bottom edge portion, and a pleated portion. The second panel defines a right side edge portion, a left side edge portion, a bottom edge portion, and a hooded portion. The first and second panels combine to define an interior and an exterior of the package. A first seam joins the right side edge portion of the first panel with the right side edge portion of the second panel. A second seam joins the left side edge portion of the first panel with the left side edge portion of the second panel. A third seam joins the bottom edge portion of the first panel with the bottom edge portion of the second panel. A line of weakness joins the pleated portion of the first panel with the hooded portion of the second panel. Upon opening the package at the line of weakness, the hooded portion may be configured in a first configuration and a second configuration. In the first configuration, the hooded portion is arranged adjacent to the pleated portion. In the second configuration, the hooded portion is arranged away from the pleated portion to form an opening in the package. Absorbent articles of the present disclosure may include diapers, feminine pads, adult incontinence products, and the like.

Packages of the present disclosure may be configured as reclosable wicketed bags. The reclosable wicketed bags may comprise a first panel and a second panel. The first panel may define a right side edge portion, a left side edge portion, a bottom edge portion, and a pleated portion. The second panel may define a right side edge portion, a left side edge portion, a bottom edge portion, and a hooded portion. The wicketed bag may comprise a wicket panel extending from the bottom edge portion of the second panel. The first and second panels combine to define an interior and an exterior of the package. A first seam joins the right side edge portion of the first panel with the right side edge portion of the second panel. A second seam joins the left side edge portion of the first panel with the left side edge portion of the second panel. A line of weakness joins the pleated portion of the first panel with the hooded portion of the second panel. The wicket panel comprises a wicket aperture. The bottom edge portion of the first panel and the bottom edge portion of the second panel combine to define an opening in the package.

A method of forming a reclosable package may include the step of advancing a continuous length of material in a machine direction, wherein the continuous length of material has a first side and a second side and defines a first edge region and a second edge region separated along a cross direction by a third region. A line of weakness may be formed along the machine direction of the central region of the continuous length of material. In some exemplary configurations, intermittently spaced wicket apertures may be formed in the machine direction along the second edge region of the continuous length of material. The continuous length of material may be folded along the central region to form a first continuous fold that extends in the machine direction. Additionally, the first continuous panel may be folded to form a continuous pleat. The continuous pleat may comprise second and third continuous folds that form first, second, and third overlapping continuous pleated portions, wherein the second and third continuous pleated portions are positioned between the first continuous pleated portion and the second panel. The line of weakness overlaps the second continuous pleated portion. The second and third continuous folds extend in the machine direction. Next, the continuous length of material may be cut in the cross direction to form a discrete package. A first seam may be formed that joins the right side edge portion of the first panel with the right side edge portion of the second panel and a second seam may be formed that joins the left side edge portion of the first panel with the left side edge portion of the second panel.

As shown in FIGS. 1-3, an exemplary package 100 for containing absorbent articles may include a first panel 102 and an opposing second panel 104, shown as a front panel and back panel, respectively. The first panel 102 defines a right side edge portion 106, a left side edge portion 108, a bottom edge portion 110, and a pleated portion 114. The second panel 104 defines a right side edge portion 107, a left side edge portion 109, a bottom edge portion 111, and a hooded portion 112. The first and second panels 102 and 104 combine to define an interior 118 and an exterior 120 of the package 100. A first seam 122 joins the right side edge portion 106 of the first panel 102 with the right side edge portion 107 of the second panel 104. A second seam 124 joins the left side edge portion 108 of the first panel 102 with the left side edge portion 109 of the second panel 104. A third seam 126 joins the bottom edge portion 110 of the first panel 102 with the bottom edge portion 111 of the second panel 104. The package 100 comprises a line of weakness 116 that joins, and at the same time demarcates, the pleated portion 114 of the first panel 102 with the hooded portion 112 of the second panel 104. The line of weakness 116 may extend contiguously with the pleated portion 114 from the right side edge portion 106 of the first panel 102 to the left side edge portion 108 of the first panel 102. The first, second, and/or third seams may be formed in various ways.

As shown in FIGS. 4A and 4B, the package 100 may contain a plurality of absorbent articles 200. Each absorbent article 200 may be folded about a lateral axis 204 and may be arranged in a horizontal or vertical row or rows. Placement of the row or rows of absorbent articles 200 into the interior 118 of the package 100 forms a substantially hexahedral shaped package having a top panel 150, bottom panel 152, front panel 158, back panel 160, left side panel 154, and right side panel 156. With reference to FIGS. 1-4B, the hooded portion 112 may define the top panel 150 of the package 100. In some exemplary configurations, the first panel 102 and a portion of the hooded portion 112 extending from the top panel 150 of the package 100 to the first panel 102 may define the front panel 158 of the package 100. The left side edge portions 108 and 109 of the first and second panels 102 and 104 may define the left side panel 154 of the package 100 and the right side edge portions 106 and 107 the first and second panels 102 and 104 may define the right side panel 156 of the package 100. The bottom edge portions 110 and 111 of the first and second panels 102 and 104 may define the bottom panel 152 of the package 100.

With reference to FIGS. 1, 2, 4A, and 4B, the package 100 may be configured such that the bottom panel 152 may be supported by a surface such as a table, countertop, floor, changing table, and the like. However, it is to be appreciated that the package 100 may be configured to rest on any of the top panel 150, bottom panel 152, front panel 158, back panel 160, left side panel 154, or right side panel 156. Further, while it is shown that the hooded portion 112 defines the top panel 150 of the package 100 and the first panel 102 and a portion of the hooded portion 112 define the front panel 158, it is to be appreciated that the hooded portion 112 of the second panel 104 and the pleated portion 114 of the first panel 102 may be arranged in various configurations such that the hooded portion 112 and the pleated portion 114 define various parts of the package 100. For example, in some exemplary configurations, the hooded portion 112 may define the back panel 160, right side panel 156 or left side panel 154 of the package 100.

With reference to FIG. 1, prior to opening the package 100 at the line of weakness 116, the package 100 may be sealed. Thus, the package 100 may be prevented from tampering or contamination until the consumer opens the package 100 to remove the first absorbent article. That is, during shipping, storage, and while at the store, the package 100 may remain sealed. In some exemplary configurations, the package 100 may be substantially hermetically sealed. As discussed in more detail below, upon opening the package 100 at the line of weakness 116, the hooded portion 112 may be configured from a first, closed configuration to a second, open configuration and back to the first, closed configuration in order to prevent contamination in between uses.

As shown in FIGS. 1 and 3, the hooded portion 112 may define the top panel 150 of the package 100 and may define a portion of the front panel 158 of the package 100. As such, the first and second seams 122 and 124 may each join the hooded portion 112 with another portion of the second panel 104. Upon opening the package 100 along the line of weakness 116, the hooded portion 112 may be arranged in a first configuration and a second configuration. As shown in FIG. 5, in the first configuration, the package 100 is substantially closed such that the hooded portion 112 is positioned adjacent to the pleated portion 114. As shown in FIG. 6, in the second configuration, the hooded portion 112 is located away from the pleated portion 114 such that a first opening 142 is formed in the package 100. As shown in FIG. 7, the hooded portion 112 may be opened in various degrees to expose different amounts of the absorbent articles 200 contained within the package 100.

As shown in FIGS. 1 and 3, in some exemplary configurations, the pleated portion 114 may be integral with the first panel 102. In such an exemplary configuration, the pleated portion 114 may comprise first and second folds 162 and 164 that form first, second, and third layers 166, 168, and 170, respectively. The first layer 166 is arranged proximate to the exterior 120 of the package 100 and the second layer 168 is arranged proximate to the interior 118 of the package 100. The third layer 170 separates the first and second layers 166 and 168. The first and third layers 166 and 170 may be joined at the first fold 162 and the second and third layers 168 and 170 may be joined at the second fold 164. The first and second folds 162 and 164 may be configured in a C-shape. In some exemplary configurations, the entire package 100, including the first and second panels 102 and 104, may be integrally formed from a single piece of material.

With reference to FIG. 3, the hooded portion 112 defines a width, W_(H), and the first panel 102 defines a width, W_(FP), in the front panel 158 of the package 100. In some exemplary configurations, the width, W_(H) of the hooded portion 112 may be less than the width, W_(FP), of the first panel 102. Or, in other exemplary configurations, the width, W_(H) of the hooded portion 112 may be greater than the width, W_(FP), of the first panel 102. A portion of the hooded portion 112 of the second panel 104 may overlap the third layer 170 and/or second layer 168 of the pleated portion 114 to define an overlap portion 140 of the hooded portion 112. The overlap portion 140 may have various widths W_(O). For example, the width W_(O) of the overlap portion 140 may be greater than 5 millimeters, or may be in the range of 10 to 100 millimeters. It is to be appreciated that the greater the width W_(O) of the overlap portion 140, the more the package 100 is actually and/or perceived to be closed in the second, closed configuration. The first, second, and third layers 166, 168, and 170 of the pleated portion 114 may have various widths. For example, the first, second, and third layers 166, 168, and 170 may have a width of greater than about 5 millimeters, or may have a width in the range of about 10 millimeters to about 200 millimeters.

In other exemplary configurations, as shown in FIGS. 8 and 9, the pleated portion 114 may comprise one or more pieces of material that are separate from the remainder of the first panel 102. For example, as shown in FIG. 9, in some an exemplary configuration, the pleated portion 114 may comprise first, second, and third layers 166, 168, and 170 that may be joined by a seam 144 that extends from the right side edge portion 106 of the first panel 102 to the left side edge portion 108 of the first panel 102. The seam 144 may be positioned proximate to the line of weakness 116 in the first panel 102 such that the package 100 is sealed prior to opening the package 100 at the line of weakness 116. In some exemplary configurations, the pleated portion 114 may comprise first and second layers 166 and 168 without the third layer 170 shown in FIG. 9. The pleated portion 114 may comprise the same or similar materials as the remainder of the first panel 102 and/or the second panel 104. In other exemplary configurations, the pleated portion 114 may comprise different materials as the first and/or second panels 102 and 104.

As shown in FIGS. 1-3, the line of weakness 116 may extend from the right side edge portion 106 of the first panel 102 to the left side edge portion 108 of the first panel 102. In such an exemplary configuration, the line of weakness 116 may be positioned in various locations relative to the top panel 150 and bottom panel 152 of the package 100. It is to be appreciated that the closer the line of weakness 116 is to the bottom edge portion 110 of the first panel 102, the greater the width, W_(H), of the hooded portion 112 in the front panel 158 of the package 100. With reference to FIG. 6, the closer the line of weakness 116 is to the bottom edge portion 110 of the first panel 102, the more exposed the absorbent articles 200 are through the first opening 142 in the package 100 when the hooded portion 112 is configured in the second, open configuration. It is to be appreciated that the line of weakness 116 may be arranged in various positions and configured in various ways. The line of weakness 116 may be positioned in the front panel 158, back panel 160, right and left side panels 156 and 154, or the bottom panel 152. The line of weakness 116 may extend through one or more panels of the package 100. In some exemplary configurations, the package 100 may include more than one line of weakness 116. As a result, the package 100 may comprise more than one first opening. As shown in FIG. 1, the line of weakness 116 may be substantially linear. However, in other exemplary configurations, the line of weakness 116 may be curved. In some exemplary configurations, the line of weakness 116 may be configured in various other shapes.

The line of weakness 116 may be ruptured by a user to gain access to the interior 118 of the package 100. The line of weakness 116 shown in FIG. 1 is configured with perforations. However, the line of weakness 116 may comprise perforations, crimps, or the like that provide a line that is weaker in structure as compared to the portions of package 100 adjacent to the line of weakness 116. It is to be appreciated that the line of weakness 116 may be strong enough to withstand shipping and handling of the package 100 without rupture, while being weak enough for a consumer to rupture the line of weakness 116 at the time of first use of the package 100.

With reference to FIGS. 1, 3, and 10, the hooded portion 112 may comprise one or more expandable gussets 128. In some exemplary configurations, the top panel 150 of the package 100 may comprise a gusset 128 having a first gusset panel 130 and a second gusset panel 132. The gusset 128 may be integrally formed with hooded portion 112 of the second panel 104. The gusset 128 may define a right side edge portion 134 and a left side edge portion 136 separated by a central portion 138. The gusset 128 may extend from the right side edge portion 107 of the second panel 104 to the left side edge portion 109 of the second panel 104. The right side edge portion 134 of the gusset 128 may be joined with the hooded portion 112 at the first seam 122 and the left side edge portion 136 of the gusset 128 may be joined with the hooded portion 112 at the second seam 124. As the package 100 is filled with absorbent articles, the right and left side edge portions 134 and 136 of the gusset 128 may become folded and tucked in toward the interior 118 of the package 100 as shown in FIG. 10. As a result, the package 100 may conform to the shape of the row or rows of absorbent articles 200 to prevent movement and/or distortion of the absorbent articles 200 during packing, shipping, and use by a consumer. While it is shown in FIG. 1 that the hooded portion 112 may comprise a gusset 128, it is to be appreciated that various other portions of the package 100 may comprise gussets. For example, the right side edge portions 106 and 107 of the first and second panels 102 and 104, the left side edge portions 108 and 109 of the first and second panels 102 and 104, and/or the bottom edge portions 110 and 111 of the first and second panels 102 and 104, may comprise a gusset.

With reference to FIGS. 1 and 2, the packages 100 of the present disclosure may comprise various materials. For example, the packages 100 may comprise films made from materials such as polyethylene or polypropylene, for example. In some exemplary configurations, package 100 comprises a polyethylene-polypropylene-polyethylene laminate. In those exemplary configurations where the package 100 comprises a laminate, the laminate may be co-extruded. The package 100 may have a thickness from about 35 microns to about 50 microns, or from about 40 to about 45 microns. In an exemplary configuration where a thicker package is desired, the package 100 may have a thickness from about 55 microns to about 65 microns.

In some exemplary configurations, components of the package can at least partially be comprised of bio-sourced content such as described in US 2007/0219521A1 Hird et al published on Sep. 20, 2007, US 2011/0139658A1 Hird et al published on Jun. 16, 2011, US 2011/0139657A1 Hird et al published on Jun. 16, 2011, US 2011/0152812A1 Hird et al published on Jun. 23, 2011, US 2011/0139662A1 Hird et al published on Jun. 16, 2011, and US 2011/0139659A1 Hird et al published on Jun. 16, 2011.

In at least one exemplary configuration, a package comprises a bio-based content value from about 10% to about 100% using ASTM D6866-10, method B, in another exemplary configuration, from about 25% to about 75%, and in yet another exemplary configuration, from about 50% to about 60% using ASTM D6866-10, method B.

In order to apply the methodology of ASTM D6866-10 to determine the bio-based content of any package, a representative sample of the package must be obtained for testing. In at least one exemplary configuration, the package can be ground into particulates less than about 20 mesh using known grinding methods (e.g., Wiley® mill), and a representative sample of suitable mass taken from the randomly mixed particles.

With reference to FIGS. 1 and 2, in some exemplary configurations, the exterior of the package 100 may comprise various images, colors, text, and the like. In some exemplary configurations, the package 100 may have indicia printed on the first and/or second panels 102 and 104, such that when the package 100 is placed with the bottom panel 152 facing down and the top panel 150 facing up, the indicia is oriented so that the indicia appears as upright. Such indicia may include words, e.g. brand name, size, product line, advertising, marketing claims, safety information, instructions for use, and the like, and/or graphics, e.g. pictures of users of the absorbent articles, caregivers, purchasers of the absorbent articles, advertising, and pictorial depictions of safety information and/or instructions for use, and the like.

With continuing reference to FIGS. 1 and 2, to aid a consumer in locating the line of weakness 116, the line of weakness 116 may be colored differently than the remainder of package 100. For example, the line of weakness may comprise a color such as blue, while the remainder of the package is a different color or is clear to draw attention to the line of weakness. In an exemplary configuration where one or more packages 100 are placed in a secondary package, such as a cardboard box, the secondary package may be provided with indicia that draws attention to line of weakness 116. For example, the secondary package may include an arrow or “tear here” statement printed on the secondary package that corresponds to the position of line of weakness 116. In some exemplary configurations, the hooded portion 112 may comprise different colors or patterns than the remainder of the package 100. For example, in such an exemplary configuration, the hooded portion 112 may be clear while the remainder of the package comprises a color and/or pattern of colors. In addition, the package 100 may comprise indicia that draws attention to the hooded portion 112 of the package 100 and/or demonstrates how to use the hooded portion 112 of the package 100. For example, an image may comprise a hand and a perspective view of the package and may demonstrate the movement of the hand relative to the package required to arrange the hooded portion in the first and second configurations.

As shown in FIG. 11, in some exemplary configurations, the package 100 may comprise a handle 146. The handle 146 may be configured in various ways. The handle 146 may be integrally formed from the first and/or second panel 102 and 104. In other exemplary configurations, the handle 146 may be a separate component that is attached to the first and/or second panel 102 and 104 of the package 100. An exemplary integrally formed handle is described in U.S. patent application titled, “PACKAGE WITH INTEGRALLY FORMED HANDLE AND A METHOD OF MAKING THE SAME”, Attorney Docket No. 12859, filed on May 22, 2013.

As shown in FIGS. 12A, 12B, and 13, prior to inserting absorbent articles into the package 100, the package 100 may be configured as a wicketed bag 148. The reclosable wicketed bag 148 may comprise a first panel 102, a second panel 104, and a wicket panel 172. The first panel 102 defines a right side edge portion 106, a left side edge portion 108, a bottom edge portion 110, and a pleated portion 114. The second panel 104 defines a right side edge portion 107, a left side edge portion 109, a hooded portion 112, and a bottom edge portion 111. The pleated portion 114 may comprise first and second folds 162 and 164 that form first, second, and third layers 166, 168, and 170, respectively. The wicket panel 172 may be connected with the bottom edge portion 111 of the second panel 104. The first and second panels 102 and 104 combine to define an interior 118 and an exterior 120 of the package 100. A first seam 122 joins the right side edge portion 106 of the first panel 102 with the right side edge portion 107 of the second panel 104. A second seam 124 joins the left side edge portion 108 of the first panel 102 with the left side edge portion 109 of the second panel 104. A line of weakness 116 joins the pleated portion 114 of the first panel 102 with the hooded portion 112 of the second panel 104. The wicket panel 172 comprises at least one wicket aperture 174, each wicket aperture 174 configured to receive a wicket. As shown in FIG. 12A, the wicket panel 172 may include two wicket apertures 174. The bottom edge portions 110 and 111 of the first and second panels 102 and 104 combine to define a second opening 176 in the package 100. The wicket panel 172 may extend beyond the bottom edge portion 110 of the first panel 102 such that the wicket panel 172 does not overlap the first panel 102.

As shown in FIG. 13, the hooded portion 112 of the wicketed bag 148 may comprise an expandable gusset 128. The gusset 128 may be integrally formed with the hooded portion 112 of the second panel 104. In such an exemplary configuration, the gusset 128 may include a first gusset panel 130 and a second gusset panel 132. The gusset 128 may form third, fourth, and fifth folds 178, 180, 182 in the second panel 104. The first gusset panel 130 may be interconnected between the third and fourth folds 178 and 180 and the second gusset panel 132 may be interconnected between the fourth and fifth folds 180 and 182. The third, fourth, and fifth folds 168, 180, and 182 may be configured as C-shape folds.

As shown in FIG. 14, a plurality of wicketed bags 148 may be stacked on top of each other such that the wicket apertures 174 of each wicketed bag 148 are aligned. A wicket 184 may extend through the wicket apertures 174 of each wicketed bag 148 to hold the stack of wicketed bags 184 together. In an exemplary configuration wherein wicketed bags 148 in a stack each comprise two wicket apertures 174, two wickets 184 may be used. Various types of wickets 184 for holding a stack of wicketed bags 148 together may be used. As discussed in more detail below, with reference to FIGS. 12A, 13, and 14, the plurality of wicketed bags 148 are held together by the wickets 184 while the absorbent articles are introduced into the wicketed bag 148 through the second opening 176. Once the wicketed bag 148 is filled with absorbent articles, the first and second panels 102 and 104 may be sealed together and the wicketed panel 172 may cut away from the second panel 104.

A reclosable wicketed bag may be formed from a single continuous length of material. As shown in FIG. 15, method of making a wicketed bag may include advancing a continuous length of material 210 in a machine direction MD. The continuous length of material 210 has a first side 212 and an opposing second side 214 and may be define a first edge region 216 and an opposing second edge region 218 separated along a cross direction by a central region 220. The continuous length of material may comprise a thermoplastic film, such as a polyethylene or polypropylene film, for example.

The continuous length of material 210 may be subjected to various operations while advancing in the machine direction MD. For example, as shown in FIG. 16, a continuous line of weakness 222 may be formed in the continuous length of material 210. The line of weakness 222 may extend along the machine direction MD and may be positioned in various cross directional CD locations. As shown in FIG. 16, in some exemplary configurations, the line of weakness 222 may extend in the machine direction MD along the central region 220 of the continuous length of material 210. The line of weakness 222 may be formed in various ways, such as by perforating, crimping, embossing, and the like to provide a line that is weaker in structure as compared to the other portions of package. The line of weakness 222 may be configured in various ways. For example, the line of weakness 222 may be substantially linear, or, in other exemplary configurations, the line of weakness may be curved.

As shown in FIG. 17, in another step, intermittently spaced wicket apertures 174 may be formed in the continuous length of material 210 along the machine direction MD. The wicket apertures 174 may be positioned in various cross directional CD locations of the continuous length of material 210. In some exemplary configurations, the wicket apertures 174 may be formed in the second edge region 218 of the continuous length of material 210. The wicket apertures 174 may be intermittently spaced at various increments in the machine direction MD. Various methods may be used to form the wicket apertures 174, including various mechanical or thermal cutting operations such as die cutting or laser cutting. The wicket apertures 174 may be sized such that a wicket may be inserted through each wicket aperture.

With reference to FIGS. 18 and 19, the continuous length of material 210 may be folded in the cross direction CD along the central region 220 to form a first continuous panel 226 and a second continuous panel 228 joined along a first continuous fold 230. The first continuous fold 230 may extend in the machine direction MD. The first continuous fold 230 may be configured in a C-shape. The second sides 214 of the first and second continuous panels 226 and 228 may be arranged in a face-to-face orientation. The first fold 230 may be positioned in various locations relative to the first and second edge regions 216 and 218 of the continuous length of material 210. As such, in some exemplary configurations, the first fold 230 may be positioned equidistant from the first and second edge regions 216 and 218. In other exemplary configurations, the first fold 230 may be positioned relatively nearer to either of the first or second edge regions 216 or 218.

With reference to FIGS. 20 and 21, in some exemplary configurations, a continuous gusset 246 may be formed in the continuous length of material 210. To form the continuous gusset 246, the continuous length of material 210 may be folded by directing a portion of the first side 212 of the continuous length of material 210 toward another portion of the first side 212 of the continuous length of material 210 such that a second continuous fold 248 and a third continuous fold 250 are formed along the machine direction MD. The continuous gusset 246 may include a first continuous gusset panel 252 and a second continuous gusset panel 254. The first continuous gusset panel 252 may be interconnected between the second continuous fold 248 and the first continuous fold 230 and the second continuous gusset panel 254 may be interconnected between the first continuous fold 230 and the third continuous fold 250. The first continuous gusset panel 252 and the second continuous gusset panel 254 may be arranged in a face-to-face relationship in substantially parallel planes. The continuous gusset 246 may be located in various cross-directional positions of the continuous length of material 210. The second and third continuous folds 248 and 250 may be configured as C-shape folds.

With reference to FIGS. 22 and 23, the continuous length of material 210 may be folded to form a continuous pleat 232. In particular, a portion of the first side 212 of the continuous length of material 210 may be directed toward another portion of the first side 212 of the continuous length of material 210 such that fourth and fifth continuous folds 234 and 236 are formed along the machine direction MD. The continuous pleat 232 may include a first continuous pleated portion 238, a second continuous pleated portion 240, and a third continuous pleated portion 242. The fourth continuous fold 234 is interconnected between the first and second continuous pleated portions 238 and 240 and the fifth continuous fold 236 is interconnected between the second and third continuous pleated portions 240 and 242. The first, second, and third pleated portions 238, 240, and 242 may be arranged in substantially parallel planes. The fourth and fifth continuous folds 234 and 236 may be located in various cross-directional CD positions of the continuous length of material 210. The continuous length of material 210 may be folded such that the continuous line of weakness 222 overlaps the second and third continuous pleated portions 240 and 242 of the continuous pleat 232. The fourth and fifth continuous folds 234 and 236 may be configured as C-shape folds. Upon folding the continuous length of material 210 to form the continuous pleat 232 and/or the continuous gusset 246, the second continuous panel 228 may extend beyond the first continuous panel 226 in the cross direction CD.

With reference to FIGS. 20-23, in some exemplary configurations, the continuous gusset 246 and the continuous pleat 232 may each extend in the machine direction MD. As such, the same or similar equipment may be used to fold the continuous length of material 210 to form the continuous gusset 246 and the continuous pleat 232. Additionally, a manufacturing line configured to manufacture a wicketed bag having a gusset may require only minimal changes to manufacture a wicketed bag having both a hooded portion and a gusset. In some exemplary configurations, the continuous gusset 246 and the continuous pleat 232 may be formed concurrently. In other exemplary configurations, the continuous gusset 246 and the continuous pleat 232 may be formed sequentially.

With reference to FIGS. 18 and 24, in another step, the continuous length of material 210 may be cut in the cross direction CD between adjacent wicket apertures 174 to form discrete wicketed bags 148. The continuous length of material 210 may be cut using various cutting apparatuses, such as a rotary knife cutter, a die cutter, or a laser cutter, for example.

The process of forming wicketed bags 148 may include the step of seaming the right and left side edge portions of the first panel, the second panel, and the gusset. With reference to FIGS. 1, 2, 3, 18, and 24, a first seam 122 may be formed in the right side edge portions 106, 107, and 134 of the first panel 102, the second panel 104, and the gusset 128, respectively. A second seam 124 may be formed in the left side edge portions 108, 109, and 136 of the first panel 102, the second panel 104, and the gusset 128, respectively. The first and second seams 122 and 124 may be formed in various ways, including ultrasonic welding, hot air seaming, adhesives, and the like. In some exemplary configurations, the steps of cutting the continuous length of material 210 to form discrete wicketed bags 148 and forming the first and/or second seams 122 and 124 may occur concurrently. In other exemplary configurations, the steps of cutting and seaming may occur sequentially.

With reference to FIGS. 13 and 24, a second opening 176 is defined by the second end portions 112 and 113 of the first and second panels 102 and 104. The wicketed bags 166 may be filled with absorbent articles by inserting the absorbent articles through the second opening 176. As discussed above, the absorbent articles may be folded about a lateral axis prior to inserting the absorbent articles into the wicketed bag. The absorbent articles may be arranged in a row with the folded end of the absorbent articles facing the gusset 140 of the wicketed bag. In some exemplary configurations, two or more rows of absorbent articles may be inserted into the wicketed bag 166.

With reference to FIGS. 2 and 25, once the wicketed bag 148 is filled with absorbent articles, the second end portions 110 and 111 of the first and second panels 102 and 104 may be joined together to form a third seam 126. Like the first and second seams 122 and 124, the third seam 126 may be formed in various ways.

Additionally, the wicket panel 172 may be cut away from the second panel 104 to form the reclosable package 100 such as shown in FIGS. 1 and 2. In some exemplary configurations, the steps of forming the third seam 126 and cutting the wicket panel 172 may occur concurrently. In other exemplary configurations, the steps of forming the third seam 126 and cutting the wicket panel 172 may occur sequentially. Various methods may be used to cut the wicket panel 172 from the second panel 104. Exemplary cutting apparatuses include knife rolls, die cutters, and lasers. As shown in FIGS. 4A and 4B, the package 100 may generally take the shape of the row of absorbent articles 200 contained therein.

It is to be appreciated that the steps described above for forming a wicketed bag may be performed in various orders. Additionally, some steps may overlap or occur concurrently, while other steps may occur sequentially.

With reference to FIGS. 1, 5, and 6, to open the package 100, a consumer may hold the first and/or third layers 166 and 170 of the pleated portion 114 of the first panel 102 with fingers from one hand and may hold the hooded portion 112 of the second panel 104 near the line of weakness 116 with fingers from the other hand. The person may rupture the line of weakness 116 by pulling their hands apart in opposite directions until the line of weakness 116 is fractured. Once the line of weakness 116 is fractured, the hooded portion 112 may be configured from the first, closed configuration to the second, open configuration.

With continuing reference to FIGS. 1, 5, and 6, when a consumer is ready to remove an absorbent article 200 from the package 100, the consumer may configure the hooded portion 112 of the package 100 from the first configuration to the second configuration. To configure the hooded portion 112 in the second configuration, the consumer may grasp the hooded portion 112 at various locations with one or both hands and simultaneously move the hooded portion 112 away from the pleated portion 114 until the absorbent articles 200 are exposed through the first opening 142 in the package 100. At the same time, the user may hold another portion of the package 100 with the opposite hand. The first opening 142 must be sufficiently large enough for an absorbent article 200 contained within the interior 118 of the package 100 to be retrieved by a user's hand and removed from the package 100. Once the user has removed an absorbent article 200 from the package 100, the user may close the hooded portion 112 of the package 100 to protect the absorbent articles 200 from contamination and tampering in between uses. To close the package 100, the hooded portion 112 of the package 100 may be positioned back in the first configuration by grasping a portion of the hooded portion 112 with one or both hands and moving the hooded portion 112 over the absorbent articles 200 and toward the pleated portion 114 of the first panel 102. At the same time, the user may hold another portion of the package 100 with the opposite hand. The steps of opening and closing the package 100 by configuring the hooded portion 112 in the first and second configurations may be repeated until all of the absorbent articles 200 are removed from the package 100.

The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm.”

Every document cited herein, including any cross referenced or related patent or application, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.

While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention. 

1. A reclosable package comprising: a first panel, wherein the first panel defines a right side edge portion, a left side edge portion, a bottom edge portion, and a pleated portion; and a second panel, wherein the second panel defines a right side edge portion, a left side edge portion, a bottom edge portion, and a hooded portion, wherein the first and second panels combine to define an interior and an exterior of the package, wherein a first seam joins the right side edge portion of the first panel with the right side edge portion of the second panel, wherein a second seam joins the left side edge portion of the first panel with the left side edge portion of the second panel, wherein a third seam joins the bottom edge portion of the first panel with the bottom edge portion of the second panel, wherein a line of weakness joins the pleated portion of the first panel with the hooded portion of the second panel.
 2. The reclosable package of claim 1, wherein the package is sealed prior to opening the package at the line of weakness.
 3. The reclosable package of claim 1, wherein the pleated portion comprises a first fold and a second fold that form a first layer, a second layer, and a third layer, wherein the first layer is arranged proximate to the exterior of the package and the second layer is arranged proximate to the interior of the package, wherein the first, second, and third layers are integrally formed with the first panel.
 4. The reclosable package of claim 1, wherein the pleated portion comprises a first layer and a second layer, wherein the first layer is arranged proximate to the exterior of the package and the second layer is arranged proximate to the interior of the package, wherein the first and second layers are formed from separate materials.
 5. The reclosable package of claim 1, wherein the hooded portion of the second panel comprises a gusset, wherein the gusset forms a top panel of the package.
 6. The reclosable package of claim 1, wherein the package comprises a plurality of absorbent articles.
 7. The reclosable package of claim 6, wherein placement of the absorbent articles into the interior of the package forms a top panel, a bottom panel, a front panel, a back panel, a left side panel and a right side panel, wherein the hooded portion defines the top panel and the pleated portion defines a portion of the front panel.
 8. The reclosable package of claim 1, wherein the package is integrally formed from a single piece of material.
 9. The reclosable package of claim 1, wherein upon opening the package at the line of weakness, the hooded portion may be arranged in a first configuration and a second configuration, wherein the hooded portion is positioned proximate to the pleated portion in the first configuration, wherein the hooded portion is positioned away from the pleated portion in the second configuration to define an opening in the package.
 10. A reclosable package comprising: a first panel, wherein the first panel defines a right side edge portion, a left side edge portion, a bottom edge portion, and a pleated portion; and a second panel, wherein the second panel defines a right side edge portion, a left side edge portion, a bottom edge portion, and a hooded portion, wherein the first and second panels combine to define an interior and an exterior of the package, wherein a first seam joins the right side edge portion of the first panel with the right side edge portion of the second panel, wherein a second seam joins the left side edge portion of the first panel with the left side edge portion of the second panel, wherein a line of weakness joins the pleated portion of the first panel with the hooded portion of the second panel, wherein the bottom edge portion of the first panel and the bottom edge portion of the second panel combine to define an opening in the package.
 11. The reclosable package of claim 10 further comprising a wicket panel connected with the bottom edge portion of the second panel, wherein the wicket panel comprises a wicket aperture.
 12. The reclosable package of claim 11, wherein a third seam joins the bottom edge portions of the first and second panels.
 13. The reclosable package of claim 10, wherein the package is integrally formed from a single piece of material.
 14. A method of forming a reclosable package, the method comprising the steps of: advancing a continuous length of material in a machine direction, wherein the continuous length of material has a first side and a second side and defines a first edge region and a second edge region separated along a cross direction by a third region; forming a line of weakness along the machine direction of the central region of the continuous length of material; folding the continuous length of material along the central region to form a first continuous fold that extends in the machine direction; folding the first continuous panel to form a continuous pleat, wherein the continuous pleat comprises second and third continuous folds that form first, second, and third overlapping continuous pleated portions, wherein the second continuous pleated portion is positioned between the first continuous pleated portion and the second continuous pleated portion, wherein the line of weakness overlaps the second continuous pleated portion, wherein the second and third continuous folds extend in the machine direction; cutting the continuous length of material in the cross direction to form a discrete package, wherein the discrete package comprises a first panel, wherein the first panel defines a right side edge portion, a left side edge portion, a bottom edge portion, and a pleated portion; and a second panel, wherein the second panel defines a right side edge portion, a left side edge portion, a bottom edge portion, and a hooded portion; wherein a line of weakness joins the pleated portion of the first panel with the hooded portion of the second panel; forming a first seam that joins the right side edge portion of the first panel with the right side edge portion of the second panel; and forming a second seam that joins the left side edge portion of the first panel with the left side edge portion of the second panel, wherein the bottom edge portion of the first panel and the bottom edge portion of the second panel combine to define an opening in the package.
 15. The method of claim 14 further comprising the step of forming a gusset along the central region of the continuous length of material, wherein the gusset comprises a fourth continuous fold and a fifth continuous fold that extend in the machine direction.
 16. The method of claim 14 further comprising the step of forming intermittently spaced wicket apertures in the machine direction along the second edge region of the continuous length of material, wherein the discrete package further comprises a wicket panel extending from the bottom edge portion of the second panel, wherein the wicket panel comprises a wicket aperture.
 17. The method of claim 16 further comprising the step of inserting a plurality of absorbent articles through the opening in the package.
 18. The method of claim 17 further comprising the step of forming a third seam that joins the bottom edge portions of the first and second panels.
 19. The method of claim 18, wherein the step of forming a third seam that joins the bottom edge portions of the first and second panels further comprises cutting the wicket panel away from the second panel.
 20. The method of claim 14, wherein the steps of cutting the continuous length of material in the cross direction to form a discrete package and forming a first seam that joins the right side edge portion of the first panel with the right side edge portion of the second panel occur concurrently. 21-40. (canceled) 